Method for manufacturing abrasive pad

ABSTRACT

A method for manufacturing an abrasive pad may include steps of forming composite materials using solvent, resin and abrasive materials; forming a plurality of strips including said composite materials through an extruder, so that the abrasive materials protrude on a surface of each stripe; disposing said strips in a container to form an abrasive pad with a predetermined thickness before the strips are solidified; and pressing said abrasive pad to a desired thickness with a pressing device. different abrasive materials can be mixed in the resin and when the abrasive material is extruded to form the strips, a plurality of gaps are formed to generate better ventilation to avoid bacteria growth. Also, the abrasive pad in the present invention can be used in for either family or industry and the manufacturing method in the present invention can extend the lives of the abrasive pad.

FIELD OF THE INVENTION

This invention relates to a method for manufacturing an abrasive pad, and more particularly to an abrasive pad made of composite materials.

BACKGROUND OF THE INVENTION

Conventionally, the method for manufacturing abrasive pads utilizes fabric as substrate and a layer of polishing material is coated thereon. The thickness of the abrasive pad is determined by the layers of the fabric.

However, conventional manufacturing method is disadvantageous because the abrasive material is merely coating on the surface of the fabric and may have to be replaced if the abrasive material falls off. It may be inconvenient for the users if the replacement is frequent. Also, current abrasive material is for more for industrial usage. For family usage, the user may want to choose the abrasive pads with different fineness for different purposes of usage. However, for scouring pads, there is no such function, and due to inadequate ventilation, bacteria may grow easily. Also, for the abrasive pad with multiple fabric layers, the manufacturing cost is high.

SUMMARY OF THE INVENTION

To solve the problems stated above, the present invention is a composite material including solvent, resin and abrasive materials, passing through an extruder to form a plurality of elongated strips. Before the strips become solidified, the elongated strips are disposed in a container to form an abrasive pad with a predetermined thickness. Furthermore, a pressuring device is used to applied certain pressure on the abrasive pad so the abrasive pad can reach a predetermined thickness, and then be cut into smaller abrasive pads.

In the present invention, different kinds of abrasive materials are dissolved in the solvent and some gaps are generated between the strips when they are disposed in the container, so the ventilation for the abrasive pad has been improved to avoid bacteria growth. Also, the abrasive pad in the present invention can be used for either family or industry.

In one embodiment, the composite material may include solvent, resin and abrasive materials, wherein the weight ratio for the solvent, resin and abrasive materials is 1:4:8. In another embodiment, the solvent is toluene. In still another embodiment, the resin is the epoxy resin. In a further embodiment, the abrasive materials include silicon carbide, garnet, aluminum oxide, silicon carbide, zirconia, diamond, ceramic, alumina and the like. In an exemplary embodiment, the abrasive pad in the present invention can be made with different ratios of the solvent, resin and abrasive materials.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a block diagram in the present invention.

FIG. 2 illustrates a schematic view of disposing the strips in the present invention.

FIG. 3 illustrates another schematic view of disposing the strips in the present invention.

FIG. 4 illustrates a schematic view of disposing the strips of another embodiment in the present invention.

FIG. 5 illustrates a schematic view pressing the abrasive materials in the present invention.

FIG. 6 illustrates a schematic view pressing the abrasive materials of another embodiment in the present invention.

FIG. 7 illustrates a sectional view of the strip in the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below is intended as a description of the presently exemplary device provided in accordance with aspects of the present invention and is not intended to represent the only forms in which the present invention may be prepared or utilized. It is to be understood, rather, that the same or equivalent functions and components may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices and materials similar or equivalent to those described can be used in the practice or testing of the invention, the exemplary methods, devices and materials are now described.

All publications mentioned are incorporated by reference for the purpose of describing and disclosing, for example, the designs and methodologies that are described in the publications that might be used in connection with the presently described invention. The publications listed or discussed above, below and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.

In order to further understand the goal, characteristics and effect of the present invention, a number of embodiments along with the drawings are illustrated as following:

Referring to FIGS. 1 to 7, a composite material 1 for an abrasive pad may include solvent 11, resin 12 and abrasive materials 13. The composite material 1 is then be disposed into an extruder 2 that has at least one output 21 to continuously form a abrasive strip 3. Before the abrasive strip 3 becomes solidified, the extruder 2 repeatedly move toward one direction (see FIGS. 2 and 3), or toward one container 4 (see FIG. 4), so that the abrasive strips 3 can be irregularly disposed in the container 4 to form an abrasive pad 5 with a predetermined thickness. Referring to FIGS. 5 and 6, a pressing device 6 can be used to press the abrasive pad 5 with a predetermined thickness so the resin 12 can be more spread out. The abrasive pad 5 can be further cut to a predetermined size according to the usage.

Still referring to FIGS. 5 and 6, the pressing device 6 can be a pressing board 61 (see FIG. 5) that can be adjusted to press the abrasive pad 5. In another embodiment, the pressing device 6 can also be a rolling wheel 61′ (see FIG. 6).

In a further embodiment, different abrasive materials 13 can be mixed in the resin 12 and when the abrasive material 13 is extruded to form the strips 3, a plurality of gaps 31 are formed to generate better ventilation to avoid bacteria growth. Also, the abrasive pad 5 in the present invention can be used in for either family or industry and the manufacturing method in the present invention can extend the lives of the abrasive pad.

Referring to FIG. 7, each strip 3 includes the abrasive materials 13 and when outer abrasive materials 13 are worn or fall off, inner abrasive materials 13 in the strip 3 can still be used, so the strip 3 can consume the resin 12 on one hand, and provide polishing effect on the other hand.

In one embodiment, the weight ratio for the solvent, resin and abrasive materials is 1:4:8. In another embodiment, the solvent 11 is toluene. In still another embodiment, the resin 12 is the epoxy resin. In a further embodiment, the abrasive materials 13 include silicon carbide, garnet, aluminum oxide, silicon carbide, zirconia, diamond, ceramic, alumina and the like.

In an exemplary embodiment, the user can choose one or more abrasive materials 13 as stated above according to the user preference and usage, and mix with the solvent 11 and resin 12 to generate abrasive pads for different usages, such as scouring pads used at home and polishing pads used in industry.

Having described the invention by the description and illustrations above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Accordingly, the invention is not to be considered as limited by the foregoing description, but includes any equivalents. 

What is claimed is:
 1. A method for manufacturing an abrasive pad comprising steps of: forming composite materials using solvent, resin and abrasive materials, forming a plurality of strips including said composite materials through an extruder, so that the abrasive materials protrude on a surface of each stripe; disposing said strips in a container to form an abrasive pad with a predetermined thickness before the strips are solidified; and pressing said abrasive pad to a desired thickness with a pressing device.
 2. The method for manufacturing an abrasive pad of claim 1, wherein the extruder has at least one output.
 3. The method for manufacturing an abrasive pad of claim 1, wherein the strips are continuously generated from the extruder and irregularly disposed in the container.
 4. The method for manufacturing an abrasive pad of claim 1, wherein the pressing device is a pressing board.
 5. The method for manufacturing an abrasive pad of claim 1, wherein the pressing device is a rolling wheel.
 6. The method for manufacturing an abrasive pad of claim 1, further comprising a step of cutting the abrasive pad according to the user's preference or usage.
 7. The method for manufacturing an abrasive pad of claim 1, wherein weight ratio for the solvent, resin and abrasive materials is 1:4:8.
 8. The method for manufacturing an abrasive pad of claim 1, wherein the solvent is toluene.
 9. The method for manufacturing an abrasive pad of claim 1, wherein the resin is epoxy resin.
 10. The method for manufacturing an abrasive pad of claim 1, wherein the abrasive materials include silicon carbide, garnet, aluminum oxide, silicon carbide, zirconia, diamond, ceramic, alumina. 